US20110219576A1 - Compact surface cleaning apparatus - Google Patents

Abstract

A surface cleaning apparatus comprises an air flow passage extending from a dirty air inlet to a clean air outlet. A suction motor is positioned in the air flow path. At least one cyclone chamber is positioned in the air flow passage. An associated dirt collection chamber is exterior to the cyclone chamber. The cyclone chamber and the suction motor are positioned side by side and have generally parallel longitudinal axes. The dirt collection chamber may surround part of the suction motor. Alternately, or in addition, a pre-motor filter having an enhanced surface area may be provided by configuring the pre-motor filter to extend outwardly of the pre-motor filter, such as by overlie part of the cyclone chamber or the dirt collection chamber.

Description

RELATED APPLICATIONS
• This application is a continuation in part of co-pending U.S. patent application Ser. No. 12/722,705, filed Mar. 12, 2010, the entirety of which being incorporated herein by reference.
FIELD
• The disclosure relates to surface cleaning apparatuses, such as vacuum cleaners.
INTRODUCTION
• The following is not an admission that anything discussed below is prior art or part of the common general knowledge of persons skilled in the art.
• Various constructions for surface cleaning apparatus such as vacuum cleaners are known. Currently, many surface cleaning apparatus are constructed using at least one cyclonic cleaning stage. The air is drawn into the vacuum cleaner through a dirty air inlet and conveyed to a cyclone inlet. The rotation of the air in the cyclone chamber results in some of the particulate matter in the airflow stream being disentrained from the airflow stream. This material is then collected in a dirt collection chamber, which may be at the bottom of the cyclone chamber or in a dirt collection chamber exterior to the cyclone chamber (see for example WO2009/026709 and U.S. Pat. No. 5,078,761). One or more additional cyclonic cleaning stages and/or filters may be positioned downstream from the cyclone chamber.
SUMMARY
• The following summary is provided to introduce the reader to the more detailed discussion to follow. The summary is not intended to limit or define the claims.
• According to one aspect, a surface cleaning apparatus, which is preferably hand carriable, is provided wherein the size, configuration and/or positioning of the dirt collection chamber may be varied so as to enable the dirt collection capacity of the unit to be increased without undesirably increasing the size of the unit or the size of the unit may be decreased without undesirably reducing the dirt collection capacity of the unit.
• In accordance with this aspect, the dirt collection chamber for a cyclone chamber is positioned to occupy at least part of the empty volume of a housing of the hand carriable surface cleaning apparatus. For example, a hand carriable surface cleaning apparatus may comprise a single first stage cyclone chamber that has an associated dirt collection chamber. In addition, a suction motor is provided, typically downstream from the cyclone chamber. Typically, the cyclone chamber and the suction motor are generally cylindrical in shape. If both components are placed in an outer housing and oriented such their longitudinal axis are parallel, then a portion of the housing of the unit will be open. According to this aspect, the dirt collection chamber is configured to occupy at least part of this open space and preferably most of this space.
• To provide a desirable outer appearance, an outer wall may be provided to encase the cyclone chamber and the suction motor. Alternately, if part of the motor casing and/or the cyclone chamber comprise part of the outer housing of the unit, an outer wall may be provided to bridge the suction motor and the cyclone chamber. This part of the housing will typically be open and may be used as part or all of a dirt collection chamber.
• A suction motor typically comprises a fan driven by a motor wherein the diameter of the fan is larger then the diameter of the motor. The wall of the motor casing is recessed inwardly from the wall of the fan casing. Therefore, there is an annular area between the outer wall of the motor casing and a projection of the location of the outer wall of the fan casing. The dirt collection chamber may alternately or in addition occupy some of all of this volume. For example, the dirt collection chamber may be constructed to comprise an annular chamber that is positioned to surround the motor casing.
• It will be appreciated that the dirt collection chamber may also surround the cyclone chamber. However, in a preferred embodiment, the dirt collection chamber surrounds only part of the cyclone chamber. A portion of the cyclone chamber is adjacent to the housing of the unit or forms part of the housing of the unit. Accordingly, the dirt collection chamber may surround about 75% or less of the cyclone chamber and preferably about 50% or less of the cyclone chamber. Accordingly, the size of the hand unit may be reduced without reducing the volume of the dirt collection chamber and, in some embodiments, the size of the dirt collection chamber may be increased.
• A further advantage of this design is that the dirt collection chamber will not be circular in cross section. Accordingly, the tendency for the air in the dirt collection chamber to develop swirling or cyclone flow will be reduced, thereby inhibiting re-entrainment of dirt into the cyclone chamber.
• A further advantage is that the dirt collection capacity may be increased without increasing the size of the unit and, in some embodiments, the size of the unit may be reduced without greatly impacting the dirt capacity of the unit. Therefore, a hand operable surface cleaning apparatus, such as a hand vacuum cleaner, may be compact so as to be useable in small spaces. Further, as the unit is operated by being held in one hand, the weight of the unit may be reduced.
• According to this aspect, a surface cleaning apparatus is provided. The surface cleaning apparatus comprises an air flow passage extending from a dirty air inlet to a clean air outlet. A suction motor is positioned in the air flow path. At least one cyclone chamber is positioned in the air flow passage. An associated dirt collection chamber is exterior to the cyclone chamber and extends at least partially along the length of the cyclone chamber. The cyclone chamber and the suction motor are positioned side by side and have generally parallel longitudinal axes. At least a portion of the dirt collection chamber is positioned between the cyclone chamber and the suction motor.
• At least a portion of the dirt collection chamber may surround at least a portion of the suction motor. The dirt collection chamber may surround the suction motor.
• At least a portion of the dirt collection chamber may surround at least a portion of the cyclone chamber. The dirt collection chamber may surround the cyclone chamber.
• The surface cleaning apparatus may further comprise a main housing, and the cyclone chamber and the suction motor may be provided in the main housing, and the dirt collection chamber may be positioned in the housing.
• The surface cleaning may further comprise a main housing, and the dirt collection chamber and the suction motor may be provided in the main housing.
• The surface cleaning apparatus may further comprise a main body, and the suction motor may be provided in the main body. The dirt collection chamber, and preferably the cyclone chamber and dirt collection chambers may be removably mounted to the main body.
• The cyclone chamber and the suction motor may each be positioned transverse to a forward direction of motion of the hand surface cleaning apparatus.
• The cyclone chamber may have a dirt outlet configured such that separated material travels from the dirt outlet to the dirt collection chamber. The dirt outlet may comprise an opening in a sidewall of the cyclone chamber.
• According to another aspect, a surface cleaning apparatus is provided. The surface cleaning apparatus may comprise an air flow passage extending from a dirty air inlet to a clean air outlet. A suction motor is positioned in the air flow passage. At least one cyclone chamber may be positioned in the air flow passage, and may have an associated dirt collection chamber exterior to the cyclone chamber. At least a portion of the dirt collection chamber surrounds at least a portion of the suction motor.
• The dirt collection chamber may surround the suction motor. The suction motor may be positioned in a motor housing and dirt chamber may surround the motor housing.
• The cyclone chamber may be parallel to the suction motor.
• The dirt collection chamber may be exterior to the cyclone chamber.
• The dirt collection chamber may have a longitudinal axis, and the suction motor may have a longitudinal angle and the axes may be generally parallel.
• The cyclone chamber and the suction motor may be provided in a housing, and the dirt collection chamber may be positioned in the housing with a portion of the dirt collection chamber positioned between the cyclone chamber and the suction motor.
• The dirt collection chamber and the suction motor may be provided in a housing and a portion of the dirt collection chamber may be positioned between the cyclone chamber and the suction motor.
• The surface cleaning apparatus may be a portable surface cleaning apparatus and the cyclone chamber and the suction motor may each be positioned transverse to a forward direction of motion of the portable surface cleaning apparatus.
• The cyclone chamber may have a dirt outlet configured such that separated material travels from the dirt outlet to the dirt collection chamber.
• The dirt outlet may comprise an opening in a sidewall of the cyclone chamber.
• The surface cleaning apparatus may further comprise a main body, and the suction motor may be provided in the main body. The dirt collection chamber, and preferably the cyclone chamber and dirt collection chambers may be removably mounted to the main body.
• The surface cleaning apparatus may be a portable surface cleaning apparatus.
• The dirt collection chamber may extend at least partially along the length of the cyclone chamber.
• According to another aspect, a surface cleaning apparatus is provided. The hand surface cleaning apparatus comprises an air flow passage extending from a dirty air inlet to a clean air outlet. A suction motor is positioned in the air flow path. At least one cyclone chamber is positioned in the air flow path and has an associated dirt collection chamber exterior to the cyclone chamber. A housing surrounds at least a portion of the suction motor and the cyclone chamber, and has an open volume exterior of the cyclone chamber and the suction motor. At least a portion of the dirt collection chamber is positioned in the open volume.
• The cyclone chamber may have an outer wall and a portion of the outer wall of the cyclone chamber may form part of the housing.
• The dirt collection chamber may have an outer wall and a portion of the outer wall of the dirt collection chamber may form part of the housing.
• The surface cleaning apparatus may further comprise a suction motor housing having an outer wall. A portion of the outer wall of the suction motor housing may form part of the housing.
• A portion of the dirt collection chamber may be positioned between the cyclone chamber and the suction motor.
DRAWINGS
• Reference is made in the detailed description to the accompanying drawings, in which:
• FIG. 1 is a perspective illustration of an embodiment of a surface cleaning apparatus;
• FIG. 2 is a cross section taken along line2-2 inFIG. 1;
• FIG. 3 is a perspective illustration of the surface cleaning apparatus ofFIG. 1, showing a second openable door in an open configuration;
• FIG. 3A is a side plan view of the surface cleaning apparatus ofFIG. 1, showing a second openable door in an open configuration;
• FIG. 3B is a perspective illustration of the surface cleaning apparatus ofFIG. 1 showing a first openable door in an open configuration;
• FIG. 4 is plan view of an alternate embodiment of a surface cleaning apparatus, showing a second openable door in an open configuration;
• FIG. 4B is plan view of another alternate embodiment of a surface cleaning apparatus, showing a second openable door in an open configuration;
• FIG. 5 is a cross section taken along the same line2-2 through an alternate embodiment of a surface cleaning apparatus;
• FIG. 6A is plan view of an alternate embodiment of a surface cleaning apparatus, showing a first openable door in an open configuration;
• FIG. 6B is a perspective illustration of the surface cleaning apparatus ofFIG. 6A;
• FIG. 7 is a perspective illustration of an alternate embodiment of a surface cleaning apparatus;
• FIG. 8 is a perspective illustration of the surface cleaning apparatus ofFIG. 7, with its cyclone bin assembly removed;
• FIG. 9 is a perspective illustration of the cyclone bin assembly ofFIG. 8;
• FIG. 10 is a section view taken along line10-10 inFIG. 7;
• FIG. 11 is a perspective illustration of an alternate embodiment of a surface cleaning apparatus;
• FIG. 12 is a perspective illustration of the surface cleaning apparatus ofFIG. 11, with its cyclone bin assembly removed;
• FIG. 13 is a perspective illustration of the cyclone bin assembly ofFIG. 12, with one end wall in an open configuration;
• FIG. 14 is a perspective illustration of the cyclone bin assembly ofFIG. 13, with the one end wall removed;
• FIG. 15 is a partially exploded view of the surface cleaning apparatus ofFIG. 11; and
• FIG. 16 is a section view taken along line16-16 inFIG. 11.
DETAILED DESCRIPTION
• Referring toFIG. 1, an embodiment of asurface cleaning apparatus200 is shown. In this embodiment thesurface cleaning apparatus200 is a hand operable surface cleaning apparatus. Thesurface cleaning apparatus200 is usable in a forward direction of motion, indicated by arrow A inFIG. 1.
• Referring toFIG. 2, thesurface cleaning apparatus200 has adirty air inlet202, a clean air outlet204 (shown inFIG. 2), and an air flow passage extending therebetween. In the embodiment shown, thedirty air inlet202 is provided in anozzle206. From thedirty air inlet202, the airflow passage extends through thenozzle206, and through anair conduit208, to a suction andfiltration unit210. Theclean air outlet204 is provided in the suction and filtration unit110. In the embodiment shown, the air conduit108 includes awand214, and ahose217.
• Referring now toFIGS. 1 and 2, the suction andfiltration unit210 includes amain housing220. A filtration member224 is provided in themain housing220, and the filtration member224 is positioned in the airflow passage downstream of thedirty air inlet202, for removing particulate matter from air flowing through the airflow passage.
• Asuction motor226 is also provided in themain housing220, downstream of the filtration member224, for drawing air through the airflow passage. Thesuction motor226 may be any suitable type of suction motor. In the embodiment shown, thesuction motor226 includes afan223, and amotor225.
• In the embodiment shown, the filtration member224 andsuction motor226 are positioned side-by-side. Further, the filtration member224 extends along anaxis246, and the suction motor extends along anaxis290, and theaxes246,290 are generally parallel. Further, the filtration member224 andsuction motor226 are each positioned transverse to the forward direction of motion (indicated by arrow A inFIG. 1) of the hand surface cleaning apparatus100.
• Referring toFIG. 1, in the embodiment shown, themain housing220 includes acentral wall230, afirst side wall232, and asecond side wall234. Thefirst side wall232 is pivotally mounted to thecentral wall230, and serves as a first openable door229. Thesecond sidewall234 has afirst portion233 adjacent the filtration member224, and asecond portion235 adjacent thesuction motor226. Thesecond sidewall234 is pivotally mounted to thecentral wall230, and serves as a second openable door231. Further, thesecond portion235 is removable from thefirst portion233.
• Referring toFIG. 2, aninterior wall237 extends within themain housing220 to separate thesuction motor226 from the filtration member224, so that fluid communication between the filtration member224 and thesuction motor226 may generally only occur between a filtrationmember air outlet264, and a suction motorair inlet end239, as will be described in further detail hereinbelow. Theinterior wall237 generally surrounds thesuction motor226 to form amotor housing227, and is integral with thecentral wall230, so that aportion269 of themotor housing227 forms part of thehousing220.
• Referring toFIG. 2, in the embodiment shown, the filtration member224 is acyclone244. In alternate embodiments, the filtration member224 may be, for example, a filter, such as a filter bag or a foam filter. In further alternate embodiments, the filtration member224 may include a plurality of cyclones, or a plurality of cyclonic stages.
• Thecyclone244 may be of any suitable configuration. Thecyclone244 includes a cyclone wall248 (also referred to as an outer wall248), which is integral with thecentral wall230, and together with thecentral wall230 defines acyclone chamber250. That is, a portion of thecyclone wall248 forms part of thehousing220. Afirst end251 of the cyclone wall148, which is positioned towards thesecond sidewall234, defines anopening252, and an opposedsecond end254 of the cyclone wall includes asecond end wall256. Thecyclone wall248 is positioned in themain housing220 such that it is spaced from thesecond sidewall234.
• The openfirst end252 of the cyclone serves as a dirt outlet for thecyclone244. Material that is separated form air in the cyclone travels from the dirt outlet to an associateddirt collection chamber260.
• Referring toFIGS. 2 and 3, at least a portion of thedirt chamber260 is preferably positioned in an open volume within themain housing220. In the embodiment shown, theentire dirt chamber260 is within an open volume within themain housing220. Thedirt collection chamber260 is preferably within themain housing220, exterior to thecyclone244 and thesuction motor226. The dirt collection chamber extends along alongitudinal axis261. Thelongitudinal axis261 is preferably parallel to thesuction motor axis290.
• Referring toFIGS. 2 and 3, at least a portion of thedirt collection chamber260 is preferably positioned between thecyclone244 and thesuction motor226. More preferably, at least a portion of thedirt collection chamber260 surrounds at least a portion of thesuction motor226 and thesuction motor housing227. For example, thedirt collection chamber260 may surround all of thesuction motor226, or only a portion of thesuction motor226, and/or all of thesuction motor housing227, or only a portion of thesuction motor housing227. As seen most clearly inFIG. 3, in the embodiment shown, thedirt collection chamber260 fully surround themotor225 ofsuction motor226 and the portionsuction motor housing227 that houses themotor225.
• Thedirt collection chamber260 further preferably surrounds at least a portion of the cyclone. For example, in the embodiment shown,dirt collection chamber260 extends around approximately one quarter of thecyclone244. In alternate embodiments, thedirt collection chamber260 may fully surround thecyclone244.
• In an alternate embodiment of asurface cleaning apparatus400 shown inFIG. 4, wherein like reference numerals are used to refer to like features as inFIGS. 1 to 3, with the first digit incremented to 4, thedirt collection chamber460 partially surrounds the motor425 ofsuction motor426 and the portionsuction motor housing427 that houses the motor425. Further, thedirt collection chamber460 partially surrounds thecyclone444. Particularly, thedirt collection chamber460 surrounds approximately three quarters of thecyclone444. In another alternate embodiment of asurface cleaning apparatus400′ shown inFIG. 5, wherein like reference numerals are used to refer to like features as inFIG. 4, with a prime (′) after the reference number, similarly to the embodiment ofFIG. 4, thedirt collection chamber460′ partially surrounds the motor425′ ofsuction motor426′ and the portionsuction motor housing427′ that houses the motor425′. Further, thedirt collection chamber460′ partially surrounds thecyclone444′. Particularly, thedirt collection chamber460′ surrounds approximately one quarter of thecyclone444′.
• Referring toFIG. 3, thedirt collection chamber260 has anouter wall263, and aportion265 of theouter wall263 preferably forms part of themain housing220.
• Thecyclone244 further includes a cyclone air inlet (not shown), and acyclone air outlet264. The cyclone air inlet extends from a first end that is in communication with thehose217 through thecentral wall230 of the filtration membermain housing220, to a second end that is in communication with thecyclone chamber250. Thecyclone air outlet264 extends along theaxis246, from afirst end270 that is positioned within thecyclone chamber250, through the lower wall156, and to a second end272 (also referred to herein as anoutlet272 of the cyclone air outlet264) that is in communication with achamber241 adjacent thefirst sidewall232 of the suction andfiltration unit210. Ascreen274 is preferably mounted over thefirst end270 of the cyclone air outlet.
• In use, air flows from thehose217 into thecyclone chamber250 through the cyclone air inlet. In thecyclone chamber250, the air flows within thecyclone wall248 in a cyclonic pattern, and particulate matter is separated from the air. The particulate matter exits thecyclone chamber250 through the openfirst end252, and settles in thedirt collection chamber260. The air exits thecyclone chamber250 through thecyclone air outlet264, and enters thechamber241
• Thedirt collection chamber260 may be emptied in any suitable manner. Referring toFIG. 3A, in the embodiment shown, thesecond side wall234 is pivotally openable, so that thedirt collection chamber260 may be opened.
• Referring still toFIG. 2, the surface cleaning apparatus includes apre-motor filter276 positioned downstream of thecyclone244 and upstream of thesuction motor226. Thepre-motor filter276 is preferably housed in thechamber241, is snugly received within thecentral wall230, overlies thesuction motor226 and thecyclone244, and spaced from the first openable door229. In the embodiment shown, thepre-motor filter276 overlies the all of thesuction motor226 and thecyclone244. In alternate embodiments, the pre-motor filter may overlie only a portion of thesuction motor226 and thecyclone244. Preferably, thepre-motor filter276 overlies at least half of thesuction motor226 and thecyclone244, and more preferably, at least 75% of thesuction motor226 and thecyclone244. Most preferably, as shown, the pre-motor filter has aportion245 that is centered over thesuction motor226 and a portion247 that overlies at least half of thecyclone226. In the embodiment shown, the portion247 overlies all of thecyclone226.
• The pre-motor filter has anupstream side280 that faces thefirst sidewall232 of themain housing220, and an opposeddownstream side282 that faces thesecond sidewall234 of themain housing220. Thepre-motor filter276 may be any suitable type of filter. Preferably, the pre-motor filter includes afoam layer286 and a feltlayer288.
• Referring still toFIG. 2, thecyclone air outlet264 extends through thepre-motor filter276, so that air exiting thepre-motor filter276 is in contact with theupstream side280 of thepre-motor filter286.
• The air then passes through thepre-motor filter276, towards a suctionmotor inlet end239 that faces thedownstream side282 of thepre-motor filter276. From thesuction motor inlet239, the air passes towards a suctionmotor outlet end243, and out of theclean air outlet204.
• Preferably, as shown inFIG. 3B, when the first openable door229 is open, theupstream side280 of the pre-motor276 is visible. By opening the openable door229, the pre-motor filter may optionally be removed, replaced, or cleaned. Further, thepre-motor filter276 is preferably mounted to at least one of thecyclone244 and thesuction motor226, and thepre-motor filter276 remains in position when the first openable door229 is opened. For example, as shown, thepre-motor filter276 is frictionally mounted to thecyclone air outlet264.
• Referring still toFIG. 2, the surface cleaning apparatus further includes ableed valve201. Thebleed valve201 allows air to flow from thesuction motor inlet239 to theclean air outlet204 so that thesuction motor226 does not burn out if a clog occurs.
• Referring toFIGS. 4 and 5, a further alternatesurface cleaning apparatus400 is shown. The surface cleaning apparatus is similar to thesurface cleaning apparatus200, and like numerals in thesurface cleaning apparatus800 will be used to describe like features as in thesurface cleaning apparatus200, with the first digit incremented to 8.
• In thesurface cleaning apparatus800, thecyclone air outlet864 does not extend through thepre-motor filter876. Theupstream side880 of thepre-motor filter876 faces towards thesecond sidewall834 of thehousing820 and faces thecyclone air outlet864, and thedownstream side882 of thepre-motor filter876 faces thefirst sidewall834. Air passes out of thesecond end872 of thecyclone air outlet864, through the pre-motor filter, and into thechamber841.
• Thesuction motor826 has a suctionmotor inlet duct853 that extends through thepre-motor filter876 to thedownstream side882 of thepre-motor filter876.
• In this embodiment, thebleed valve801 is provided in the openable door, and has anair outlet805 that is within thechamber841, so that it is in communication with the suction motorair inlet end839.
• When the openable door is open, thesuction motor inlet839 is visible, and thedownstream side882 of thepre-motor filter876 is visible.
• Referring toFIGS. 6A and 6B, a further alternatesurface cleaning apparatus900 is shown. The surface cleaning apparatus is similar to thesurface cleaning apparatus200, and like numerals in thesurface cleaning apparatus900 will be used to describe like features as in thesurface cleaning apparatus200, with the first digit incremented to 9.
• In thesurface cleaning apparatus900, the post motor filter976 overlies only the motor (not shown) and themotor housing927, and does not overlie the cyclone944. Thecyclone outlet964 is in communication with the upstream side980 of the post motor filter976, which faces towards thefirst side232 of thehousing220. The downstream side of the post motor filter976 faces the motor inlet end (not shown) and thesecond side234 of thehousing920. Ableed valve901 extends through the post motor filter976.
• Referring toFIGS. 7-10, a further alternatesurface cleaning apparatus1100 is shown. In the embodiment illustrated, thesurface cleaning apparatus1100 is a hand operable surface cleaning apparatus. In alternate embodiments, the surface cleaning apparatus may be another suitable type of surface cleaning apparatus, including, for example, an upright vacuum cleaner, a canister vacuum cleaner, a stick vacuum cleaner, a wet-dry vacuum cleaner and a carpet extractor.
• Referring toFIG. 10, thesurface cleaning apparatus1100 has adirty air inlet1102, aclean air outlet1104 and an airflow passage extending therebetween. In the embodiment shown, thedirty air inlet1102 is the air inlet1106 of asuction hose connector1108 that can be connected to the downstream end of, e.g., a flexible suction hose or other type of cleaning accessory tool, including, for example, a wand and a nozzle. From thedirty air inlet1102, the airflow passage extends through an air treatment member that can treat the air in a desired manner, including for example removing dirt particles and debris from the air. In the illustrated example, the air treatment member comprises acyclone bin assembly1110. Thecyclone bin assembly1110 is mounted on abody1112. Alternatively, or in addition, the air treatment member can comprise a bag, a filter or other air treating means. Asuction motor1114 that is mounted within thebody1112 and is in fluid communication with thecyclone bin assembly1110.
• Theclean air outlet1104, which is in fluid communication with an outlet of thesuction motor1114, is provided in thebody1112. In the illustrated example, thedirty air inlet1102 is located toward the front of thesurface cleaning apparatus1100, and theclear air outlet1104 is located toward the rear.
• In the illustrated example,cyclone bin assembly1110 includes acyclone chamber1118 and adirt collection chamber1120. Thecyclone chamber1118 is bounded by a sidewall1122, afirst end wall1124 and asecond end wall1126 that are configured to provide an inverted cyclone configuration. Atangential air inlet1128 is provided in the sidewall of thecyclone chamber1118 and is in fluid communication with the air outlet of thehose connector1108. Air flowing into thecyclone chamber1118 via thetangential air inlet1128 can circulate around the interior of thecyclone chamber1118 and dirt particles and other debris can become disentrained from the circulating air.
• Aslot1132 formed between the sidewall1122 and thesecond end wall1126 serves as acyclone dirt outlet1132. Debris separated from the air flow in thecyclone chamber1118 can travel from thecyclone chamber1118, through thedirt outlet1132 to thedirt collection chamber1120.
• Air can exit thecyclone chamber1118 via an air outlet. In the illustrated example, the cyclone air outlet includes avortex finder1134. Optionally, aremovable screen1136 can be positioned over thevortex finder1134. Thecyclone chamber1118 extends along alongitudinal cyclone axis1138. In the example illustrated, thelongitudinal cyclone axis1138 is aligned with the orientation of thevortex finder1134.
• Thedirt collection chamber1120 comprises asidewall1140, afirst end wall1142 and an opposingsecond end wall1144. In the illustrated example, at least a portion of the dirtcollection chamber sidewall1140 is integral with a portion of the cyclone chamber sidewall1122, and at least a portion of the firstcyclone end wall1124 is integral with a portion of the first dirt collectionchamber end wall1142.
• Referring toFIG. 8, thecyclone bin assembly1110 is optionally detachably connected to thebody1112. In the example illustrated, thecyclone bin assembly1110 is detachably mounted on aplatform1148. Areleasable latch1150 can be used to secure a front edge of thecyclone bin assembly1110 to thebody1112.
• Referring toFIG. 7, ahandle1152 is provided on the top of thecyclone bin assembly1110. Thehandle1152 is configured to be grasped by a user. When thecyclone bin assembly1110 is mounted on thebody1112, thehandle1152 can be used to manipulate thesurface cleaning apparatus1100. When thecyclone bin assembly1110 is removed from thebody1112, thehandle1152 can be used to carry the cyclone bin assembly110, for example to position thecyclone bin assembly1110 above a waste receptacle for emptying. In the illustrated example, thehandle1152 is integral with alid1154 of the cyclone bin assembly110.
• Referring toFIGS. 9 and 10, the dirtcollection chamber sidewall1140 comprises arecess1214 that is shaped to receive a corresponding portion of thebody1112. In the illustrated example, therecess1214 is shaped to receive a portion of themotor housing1216 surrounding thesuction motor1114. In this example, at least a portion of thedirt collection chamber1120 is positioned between thecyclone chamber1118 and thesuction motor1114. Preferably, at least a portion of thedirt collection chamber1120 surrounds at least a portion of thesuction motor1114 and, if a suction motor housing is provided, thesuction motor housing1216. In the illustrated example, thedirt collection chamber1120 surrounds only a portion of themotor housing1216. The shape of therecess1214 is preferably selected to correspond to the shape of thesuction motor housing1216 so as to maximize the size of the dirt collection chamber for the foot print of the vacuum cleaner. Configuring thedirt collection chamber1120 to at least partially surround the suction motor housing216 may help reduce the overall length of thesurface cleaning apparatus1100, and/or may help increase the capacity of thedirt collection chamber1120.
• Referring toFIG. 10, thedirt collection chamber1120 also surrounds at least a portion of thecyclone chamber1118. Optionally, thedirt collection chamber1120 can be configured to completely surround thecyclone chamber1118.
• Air exiting thecyclone chamber1118 flows to asuction motor1114 inlet via anfilter chamber1186. Thefilter chamber1186 is provided downstream from the cyclone air outlet. In the illustrated example, thefilter chamber1186 extends over substantially the entire lower portion of thebody1112 and overlies substantially all of thecyclone chamber1118,dirt collection chamber1120 andsuction motor1114.
• Apre-motor filter1218 is provided in thefilter chamber1186 to filter the air before it enters thesuction motor inlet1220. Thepre-motor filter1218 is sized to cover the entire area of thefilter chamber1186, and overlies substantially all of thecyclone chamber1118,dirt collection chamber1120 andsuction motor1114. Preferably, the cross sectional area (in the direction of air flow) of thepre-motor filter1218 is greater than the cross sectional area of thecyclone chamber1118 and thesuction motor1114. In the illustrated example, thepre-motor filter1218 comprises first and secondpre-motor filters1218a,1218b. Thefilter chamber1186 comprises anair inlet chamber1222 on theupstream side1224 of thepre-motor filter1218, and an air outlet chamber1226 on thedownstream side1228 of thepre-motor filter1218. Air can travel from theair inlet chamber1222 to the air outlet chamber1226 by flowing through the air-permeablepre-motor filter1218. It will be appreciated that the larger the cross sectional area of the upstream face of the filter, the greater the capacity of the filter to filter particulates without the filter becoming clogged. Accordingly, it is preferred to makepre-motor filter1218 as large as possible. Accordingly, it is preferred thatfilter chamber1186 is as large as possible (i.e. it overlies all of an end face of the cyclone chamber, dirt collection chamber and suction motor) and that thepre-motor filter1218 extends over the full transverse extent offilter chamber1186. It will be appreciated that thefilter chamber1186 may overlie only a portion of the end face of the cyclone chamber, dirt collection chamber and suction motor but may still provide a larger upstream surface area then is the filter only overlied the cyclone chamber.
• The lower side of the air filtration chamber comprises a filtrationchamber end wall1244. Optionally, thefirst end wall1244 of thefilter chamber1186 can be openable to allow a user to access thepre-motor filter1218. In the illustrated example, the filterchamber end wall1244 is pivotally connected to thebody1112 by a hinge1246 and can pivot to an open position. Thereleasable latch1150 can be used to secure in a closed position. Thelatch1150 can connect the filterchamber end wall1244 to thecyclone bin assembly1110. As exemplified and discussed hereafter, the upstream side ofpre-motor filter1218 is visible when filterchamber end wall1244 is in the open position and accordingly, a user may readily detect if thepre-motor filter1218 requires cleaning or changing.
• Theair inlet chamber1222 is fluidly connected to the cyclone chamber air outlet by aninlet conduit1230 that extends through thepre-motor filter1218. In the illustrated example theinlet conduit1230 comprises an extension of a vortex finder insert. The air outlet chamber1226 is in fluid communication with theinlet1220 of thesuction motor1114. Thepre-motor filter1218 may be supported by a plurality of support ribs1232 extending through the air outlet chamber1226. Gaps or cutouts can be provided in the ribs1232 to allow air to circulate within the air outlet chamber1226 and flow toward thesuction motor inlet1220. From thesuction motor inlet1220, the air is drawn through thesuction motor1114 and ejected via asuction motor outlet1116. Optionally, a post-motor filter1236 (for example a HEPA filter) can be provided downstream from thesuction motor outlet1116, between thesuction motor outlet1116 and theclean air outlet1104. Adetachable grill1238 can be used to retain thepost-motor filter1236 in position, and allow a user to access thepost-motor filter1236 for inspection or replacement.
• Referring toFIGS. 11 to 16, another embodiment of asurface cleaning apparatus2100 is shown. In the embodiment illustrated, thesurface cleaning apparatus2100 is a canister vacuum cleaner. Thesurface cleaning apparatus2100 has adirty air inlet2102, aclean air outlet2104 and an airflow passage extending therebetween. In the embodiment shown, thedirty air inlet2102 is the air inlet of asuction hose connector2106 that can be connected to the downstream end of a flexible suction hose or other type of cleaning accessory tool, including, for example, a surface cleaning head, a wand and a nozzle. From thedirty air inlet2102, the airflow passage extends through an air treatment member2108 that can treat the air in a desired manner, including for example removing dirt particles and debris from the air. In the illustrated example, the air treatment member2108 comprises acyclone bin assembly2110. Alternatively, or in addition, the air treatment member2108 can comprise a bag, a filter or other air treating means. A suction motor2111 (FIG. 16) is mounted within abody2112 of thesurface cleaning apparatus2100 and is in fluid communication with thecyclone bin assembly2110. In the illustrated example, thebody2112 of thesurface cleaning apparatus2100 is a rollable, canister-type body that comprises aplatform2114 and two opposingsidewalls2116a,2116bthat cooperate to define acentral cavity2118. Thesurface cleaning apparatus2100 also comprises twomain side wheels2120a,2120b, rotatably coupled to thesidewalls2116aand2116b, respectively.
• Theclean air outlet2104, which is in fluid communication with an outlet of thesuction motor2111, is provided in thebody2112. In the illustrated example, thedirty air inlet2102 is located toward thefront2122 of thesurface cleaning apparatus2100, and the clear air outlet is located toward the rear2124.
• In the illustrated example, the body sidewalls2116a, bare generally circular and cover substantially the entire side faces of thesurface cleaning apparatus2100. Onemain side wheel2120a,2120bis coupled to the outer face of each body sidewall2116aand2116b, respectively. Optionally, theside wheels2120a,2120bmay have alarger diameter2126 than the body sidewalls2116a, band can completely cover the outer faces of thesidewalls2116a, b. Referring toFIG. 16, eachside wheel2120a, bis rotatably supported by a correspondingaxel2128a,2128b, which extends from the body sidewalls2116aand2116b, respectively. Themain side wheels2120aand2120bare rotatable about a primary axis ofrotation2130. In the illustrated example, the primary axis ofrotation2130 passes through thecyclone bin assembly2110.
• Optionally, at least one of the side wheels120a, bcan be detachable from the body112. Referring toFIG. 15, in the illustratedexample side wheel2120ais detachably coupled to itscorresponding axels2128aby a threaded hub assembly2132a, and can be removed from thebody2112. Removing theside wheel2120afrom the body112, or otherwise positioning them in an open configuration, may allow a user to access a variety of components located in compartments between the side wheels120aand120band the corresponding sidewalls116aand116b, as explained in greater detail below.
• FIGS. 12,13,14 and16 illustrated an example of acyclone bin assembly2110 includes acyclone chamber2162 and adirt collection chamber2164 in accordance with one embodiment. Thecyclone bin assembly2110 is detachably mounted in thecavity2118, laterally between the sidewalls2116a,2116bandside wheels2120a,2120b. Positioning thecyclone bin assembly2110 in thecavity2118, between the body sidewalls2116a,2116bmay help protect thecyclone bin assembly2110 from side impacts, for example if thesurface cleaning apparatus2100 contacts a piece of furniture or other obstacle. Preferably, the body sidewalls2116a,2116bhave a larger cross-sectional area than thecyclone bin assembly2110. More preferably, the transverse faces of thecyclone bin assembly2110 are entirely covered by the body sidewalls2116a,2116b.
• In the illustrated example, thecyclone chamber2162 is bounded by asidewall2166, afirst end wall2168 and asecond end wall2170. Atangential air inlet2172 is provided in the sidewall of thecyclone chamber2162 and is in fluid communication with thedirty air inlet2102. Air flowing into thecyclone chamber2162 via the air inlet can circulate around the interior of thecyclone chamber2162 and dirt particles and other debris can become disentrained from the circulating air.
• Aslot2180 formed between thesidewall2166 and thesecond end wall2170 serves as acyclone dirt outlet2180. Debris separated from the air flow in thecyclone chamber2162 can travel from thecyclone chamber2162, through thedirt outlet2180 to thedirt collection chamber2164.
• Air can exit thecyclone chamber2162 via an air outlet. In the illustrated example, the cyclone air outlet includes avortex finder2182. Optionally, aremovable screen2183 can be positioned over thevortex finder2182. Thecyclone chamber2162 extends along alongitudinal cyclone axis2184. In the example illustrated, the longitudinal cyclone axis is aligned with the orientation of thevortex finder2182 and is generally transverse to the direction of movement of thesurface cleaning apparatus2100. Thecyclone chamber2162 has a generally circular cross sectional shape (taken in a plane perpendicular to the cyclone axis) and has acyclone diameter2186.
• Thedirt collection chamber2164 comprises asidewall2174, afirst end wall2176 and an opposingsecond end wall2178. In the illustrated example, at least a portion of the dirtcollection chamber sidewall2174 is integral with a portion of thecyclone chamber sidewall2166, and at least a portion of the firstcyclone end wall2168 is integral with a portion of the first dirt collectionchamber end wall2176.
• Referring toFIGS. 12 and 14, alower surface2188 of thecyclone bin assembly2110 is configured to rest on theplatform2114, and the first andsecond end walls2168,2170 of thecyclone bin assembly2110 are shaped to engage the inner surfaces of the body sidewalls2116a,2116b, respectively. The upper portion of the cyclone bin (as viewed when installed in the cavity2118) can have a radius of curvature that generally corresponds to the radius of curvature of the body sidewalls2116a,2116band theside wheels2120a,2120b. Matching the curvature of thecyclone bin assembly2110 with the curvature of the side wheels120a,120bmay help facilitate mounting of thecyclone bin assembly2110 within thebody2112, so that the walls of thecyclone bin assembly2110 do not extend radially beyond the body sidewalls2116a,1216bormain side wheels2120a,2120b.
• Referring toFIG. 13, the second dirt collectionchamber end wall2178 is preferably pivotally connected to the dirtcollection chamber sidewall2174. The second dirt collectionchamber end wall2178 can be opened to empty dirt and debris from the interior of thedirt collection chamber2164. Optionally, the secondcyclone end wall2170 is integral with and is openable with the second dirt collectionchamber end wall2178. Opening the secondcyclone end wall2170 can allow dirt and debris to be emptied from thecyclone chamber2162. The second dirtcollection chamber sidewall2178 can be retained in the closed position by areleasable latch2204. Optionally, thescreen2183 and/or thevortex finder2182 can be removable from thecyclone chamber2162 and can be removed when the second dirt collectionchamber end wall2178 is open.
• Referring toFIGS. 13 and 14, the dirtcollection chamber sidewall2174 comprises arecess2206 that is shaped to receive a corresponding portion of thebody2112. Referring toFIG. 12, in the illustrated example, theplatform2114 comprises a generallyplanar bearing surface2208 for supporting thecyclone bin assembly2110. Theplatform2114 also comprises at least a portion of thesuction motor housing2210 surrounding thesuction motor2111. In this example, therecess2206 in the dirtcollection chamber sidewall2174 is shaped to receive the portion of themotor housing2210 projecting above theplanar bearing surface2208.
• Preferably, at least a portion of thedirt collection chamber2164 surrounds at least a portion of thesuction motor2111 and thesuction motor housing2210. In this example, at least a portion of thedirt collection chamber2164 is positioned between thecyclone chamber2162 and the suction motor housing2210 (and thesuction motor2111 therein). Configuring thedirt collection chamber2164 to at least partially surround thesuction motor housing2210 may help reduce the overall size of thesurface cleaning apparatus2100, and/or may help increase the capacity of thedirt collection chamber2164. Thedirt collection chamber2164 also surrounds at least a portion of thecyclone chamber2162.
• Referring toFIGS. 15 and 16, air exiting thecyclone chamber2162 flows to asuction motor inlet2246 via afilter chamber2248. Thefilter chamber2248 is provided downstream from the cyclone air outlet. In the illustrated example, thefilter chamber2248 comprises a recessed chamber in thebody sidewall2116athat is enclosed by anopenable seal plate2250. A sealinggasket2254 is provided at the interface between anannular rim2252 of thesidewall2116aand theseal plate2250 to help provide an air-tight filter chamber2248. In the illustrated example, thefilter chamber2248 extends over substantially theentire sidewall2116aand overlies substantially all of the transverse cross sectional area ofcyclone chamber2162,dirt collection chamber2164 andsuction motor2111.
• Apre-motor filter2256 is provided in thefilter chamber2248 to filter the air before it enters the suction motor inlet. Thepre-motor filter2256 is sized to cover substantially the entire area of thefilter chamber2248, and overlies substantially all of the transverse cross sectional area of thecyclone chamber2162,dirt collection chamber2164 andsuction motor2111. In the illustrated example, thepre-motor filter2256 comprises first and secondpre-motor filters2256a,2256b. Thefilter chamber2248 comprises anair inlet chamber2258 on the upstream side of thepre-motor filter256, and anair outlet chamber2260 on the downstream side of thepre-motor filter2256. Air can travel from theair inlet chamber2258 to theair outlet chamber2260 by flowing through thepre-motor filter2256.
• Theair inlet chamber2258 is fluidly connected to thevortex finder2182 by aninlet conduit2262 that extends through afirst aperture2264 in thepre-motor filter2256. Theair outlet chamber2260 is in fluid communication with theinlet2246 of thesuction motor2111. Thepre-motor filter2256 can be supported by a plurality ofsupport ribs2266 extending from thesidewall2116ainto theair outlet chamber2260. Cutouts can be provided in the ribs to allow air to circulate within theair outlet chamber2266 and flow toward thesuction motor inlet2246.
• In the illustrated example, theaxle2128afor supporting the side wheel extends through theair filter chamber2248, a second aperture2268 in thepre-motor filter2256 and through anaxel aperture2270 in theseal plate2250. Theaxle aperture2270 in theseal plate2250 is configured to provide an air-tight seal against theaxel2128a. Optionally, a sealing gasket can be provided at the interface between theseal plate2250 and theaxel2128a. In this configuration thepre-motor filter2256 surrounds theaxel2128a.
• In the illustrated example, theseal plate2250 is removable, when theside wheel2120ais detached, to allow a user to access thepre-motor filter2256. Alternatively, instead of being removable, theseal plate2250 can be movably attached to thebody2112, for example pivotally connected to thesidewall2116a, such that theseal plate2250 can be opened without being completely detached from thebody2112.
• Preferably, theseal plate2250 is transparent, or at least partially transparent. Providing atransparent seal plate2250 may help facilitate visual inspection of theupstream side2272 of thepre-motor filter2256 while theseal plate2250 is in place. When theseal plate2250 is removed, thepre-motor filter2256 may be removed, for example for cleaning or replacement.
• A bleed valve is provided to supply clean air to the suction motor inlet. In the illustrated example a bleedvalve air outlet2278 is in fluid communication with theair outlet chamber2260 and can introduce clean air into theair outlet chamber2260 downstream from thepre-motor filter2256. Air introduced by the bleed valve can flow through the cutouts in the supportingribs2266, as described above. The bleed valve may be a pressure sensitive valve that is opened when there is a blockage in the air flow path upstream from thesuction motor2111. In the illustrated example, the bleed valve is parallel with thesuction motor2111. A bleed valve inlet2280 (see alsoFIG. 11) is provided toward the front of thebody2112.
• It will be appreciated that, in one embodiment, the enhanced dirt collection chamber construction may be used by itself without the enhanced filter chamber design. Alternately, both the enhanced dirt collection chamber construction and the enhanced filter chamber design may be used concurrently as exemplified herein. It will also be appreciated that the cyclone chamber may be of any design and configuration. When either of the enhanced dirt collection chamber construction and/or the enhanced filter chamber design are used, the vacuum cleaner may be of any design and the dirt collection chamber may or may not be removably mounted from the vacuum cleaner.
• Various apparatuses or methods are described above to provide an example of each claimed invention. No example described above limits any claimed invention and any claimed invention may cover processes or apparatuses that are not described above. The claimed inventions are not limited to apparatuses or processes having all of the features of any one apparatus or process described above or to features common to multiple or all of the apparatuses described above.

Claims (30)

1. A surface cleaning apparatus comprising:

(a) an air flow passage extending from a dirty air inlet to a clean air outlet;

(b) a suction motor positioned in the air flow path; and,

(c) at least one cyclone chamber positioned in the air flow passage and an associated dirt collection chamber exterior to the cyclone chamber and extending at least partially along the length of the cyclone chamber, the cyclone chamber and the suction motor are positioned side by side and have generally parallel longitudinal axes, wherein at least a portion of the dirt collection chamber is positioned between the cyclone chamber and the suction motor.

2. The surface cleaning apparatus ofclaim 1 wherein at least a portion of the dirt collection chamber surrounds at least a portion of the suction motor.

3. The surface cleaning apparatus ofclaim 1 wherein the dirt collection chamber surrounds the suction motor.

4. The surface cleaning apparatus ofclaim 1 wherein at least a portion of the dirt collection chamber surrounds at least a portion of the cyclone chamber.

5. The surface cleaning apparatus ofclaim 1 wherein the dirt collection chamber surrounds the cyclone chamber.

6. The surface cleaning apparatus ofclaim 1 further comprising a main housing and the cyclone chamber and the suction motor are provided in the main housing.

7. The surface cleaning apparatus ofclaim 1 further comprising a main housing and the dirt collection chamber and the suction motor are provided in the main housing.

8. The surface cleaning apparatus ofclaim 1 further comprising a main body and the suction motor is provided in the main body and the cyclone chamber and the dirt collection chamber are removably mounted to the main body.

9. The surface cleaning apparatus ofclaim 1 wherein the cyclone chamber and the suction motor are each positioned transverse to a forward direction of motion of the hand surface cleaning apparatus.

10. The surface cleaning apparatus ofclaim 1 wherein the cyclone chamber has a dirt outlet configured such that separated material travels from the dirt outlet to the dirt collection chamber.

11. The surface cleaning apparatus ofclaim 10 wherein the dirt outlet comprises an opening in a sidewall of the cyclone chamber.

12. A surface cleaning apparatus comprising:

(a) an air flow passage extending from a dirty air inlet to a clean air outlet;

(b) a suction motor positioned in the air flow passage; and,

(c) at least one cyclone chamber positioned in the air flow passage and having an associated dirt collection chamber wherein at least a portion of the dirt collection chamber surrounds at least a portion of the suction motor.

13. The surface cleaning apparatus ofclaim 12 wherein the dirt collection chamber surrounds the suction motor.

14. The surface cleaning apparatus ofclaim 13 wherein the suction motor is positioned in a motor housing and dirt chamber surrounds the motor housing.

15. The surface cleaning apparatus ofclaim 12 wherein the cyclone chamber is parallel to the suction motor.

16. The surface cleaning apparatus ofclaim 12 wherein the dirt collection chamber is exterior to the cyclone chamber.

17. The surface cleaning apparatus ofclaim 12 wherein the dirt collection chamber has a longitudinal axis and the suction motor has a longitudinal angle and the axes are generally parallel.

18. The surface cleaning apparatus ofclaim 12 wherein the cyclone chamber and the suction motor are provided in a housing and the dirt collection chamber is positioned in the housing with a portion of the dirt collection chamber positioned between the cyclone chamber and the suction motor.

19. The surface cleaning apparatus ofclaim 12 wherein the dirt collection chamber and the suction motor are provided in a housing and a portion of the dirt collection chamber is positioned between the cyclone chamber and the suction motor.

20. The surface cleaning apparatus ofclaim 12 wherein the surface cleaning apparatus is a portable surface cleaning apparatus and the cyclone chamber and the suction motor are each positioned transverse to a forward direction of motion of the portable surface cleaning apparatus.

21. The surface cleaning apparatus ofclaim 12 wherein the cyclone chamber has a dirt outlet configured such that separated material travels from the dirt outlet to the dirt collection chamber.

22. The surface cleaning apparatus ofclaim 21 wherein the dirt outlet comprises an opening in a sidewall of the cyclone chamber.

23. The surface cleaning apparatus ofclaim 12 further comprising a main body and the suction motor is provided in the main body and the cyclone chamber and the dirt collection chamber are removably mounted to the main body.

24. The surface cleaning apparatus ofclaim 12 wherein the surface cleaning apparatus is a portable surface cleaning apparatus.

25. The surface cleaning apparatus ofclaim 12 wherein the dirt collection chamber extends at least partially along the length of the cyclone chamber.

26. A surface cleaning apparatus comprising:

(a) an air flow passage extending from a dirty air inlet to a clean air outlet;

(b) a suction motor positioned in the air flow path;

(c) at least one cyclone chamber positioned in the air flow path and having an associated dirt collection chamber exterior to the cyclone chamber; and,

(d) a housing surrounding at least a portion of the suction motor and the cyclone chamber and having an open volume exterior of the cyclone chamber and the suction motor, wherein at least a portion of the dirt collection chamber is positioned in the open volume.

27. The surface cleaning apparatus ofclaim 26 wherein the cyclone chamber has an outer wall and a portion of the outer wall of the cyclone chamber forms part of the housing.

28. The surface cleaning apparatus ofclaim 26 wherein the dirt collection chamber has an outer wall and a portion of the outer wall of the dirt collection chamber forms part of the housing.

29. The surface cleaning apparatus ofclaim 26 further comprising a suction motor housing having an outer wall wherein a portion of the outer wall of the suction motor housing forms part of the housing.

30. The surface cleaning apparatus ofclaim 26 wherein a portion of the dirt collection chamber is positioned between the cyclone chamber and the suction motor.

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